Method of making faced concrete products



Feb. 28,1933. w. H. cRUME METHOD OF MAKING FACED CONCRETE PRODUCTS Filed Jan. 22, 1930 2 Sheets-Sheet l Feb. 28, 1933. w.. H. cRuME METHOD OF MAKING FACED CONCRETE PRODUCTS Filed Jan. 22 1930 o o ov o o O O o gli g 8 3m g 0 9 q' N 2 Sheets-Sheet 2 HOURS Cranz/e,

Patented Feb. 28, 1933y UNITED s@'rrxr;Es

OFFICE- Winnmnmonumnz or. IJAYTON," OHIO, AssIGNoR mo iTnE MACGLASHAN CORPORA- Y TION, or f'rEcUMsrEILvMIcHIeAmA CORPORATION or DELAWARE l iMnfrHOnpoF MAKINGEFAOED .CONCRETE PRoDUo'rs ,'Apiicaion metv Jaaryez, 1930. serial No. 422,635.

concrete building units such as face tile ork blocks, concrete floor, tilej'andlcast stone, have vbeen manufacturedfor a number of years to Abe used in substitution-for natural `rock and l burned clay products.y W'hile concrete'products have been found to be quite satisfactory' when manufactured under rei-y favorable and exact conditions, there havebeen, neverytheless, many objections@ the useof 1th@ same.y In some instances Wasfound that the process of manufacturing concrete products whereby. sufficient strengthjvvould be had lto permit ai substitution .for natural j 'gravel or natural'rock screenings, and Portrocks, consumedso .muchtimeand the expense thereof was suchthat burned` clay produc-ts and krquite koften natural rock would be obtained at a lower cost.rv `Heretofore the use of concrete products 'as face runits for either exterior or interior` purposes has been limitedas the appearance and texture of the products manufactured by the usualt methods, as Well asthey customary size, shape and Weight, made themobjectionablej for` vsuch use. Y y 1;..

i Because of. thefactthat the normal appearanceand texture of concrete building units' makes them objectionablev formany purposes,'the usefof such l,products has been .greatly limited. vrflierefore,.,many attemptsV have been made yto find` a Asolution for the;l difficulties encountered,andy one Way' in whichA the obj ecti onghas vbeen somejvhatV eliminated is by using the products'onlyasa back-up4 in floor .or., Wall. constructions.

fHowever, such practice fof usingthe prodf l ucts forbaclrup purposes necessitated fao-* ing theksaine with someimaterial such'as stucco, plaster,` clay products,vvall boards vor slabs, Vor natural `cut stone, andv therefore other problems Were ,pijiflsentedy Itfhas been found that the practiceof facing the 'prodcts is very' 'costly, duetotheuse of the' extra materials an'dbecause ai prolonged *pe` riod 'of time is required' in theconstruction of buildings intlismannerx'" -v n The Predial limitations Tte fthe? use 0f ordinary concrete products have been recogf nizedfor some years, not only in so far as temptingrto eliminatethe necessity for fac-r Jing the products, or to avoid a decided modiication of the normal process of'manufa'cture, there has been considerable activity tending to develop a simplified process ofy coloring the.v surfaces of the ordinary prod-4 ucts 'or of treatingI the surfaces to render nowc'onnnercial process'has previously been developed which' will answer all ofthe requirements of the art.- j y l Facings formed of :aggregate such as sand,

' the products themselves are concerned, but'y i also in the facing of the products'. In at- 'th-em of an improved appearance of a last-V `ingnature. However, so far asl am aware, n'

land cement, in some instances combined with which is capable of being usedimmediately upon' being discharged from the apparatus,

Without any tendency toward undue shrink-A age of the product in use, and Which is: suita-` ble for outside or interiory Walls of buildings;

The invention .also contemplates the formation of concrete produc's having a face and aV back-up portion, and which possesses fun-V,

usually highstrength as compared to products4 now intended tobe, used for similar purposes, said'products being of uniform quality and lpresenting a greatly improved appearance. l LAnother objectfof `this invention is the formation of concrete productsv which' are light invveightand yet possess high strength whichy provide an effective insulation against heat or cold, areire and Weather-resistingf` and still present a pleasing appearance.

appearance, and to produce such a product f Afurther object of ythis yinvention is thel 'i y provision'of aproces's by Which concrete slabs may be made in substantially predetermined colors, in ydelicate tintsor with grained eiects, and with a back-up of sand and Ltreatment without ettecting cracking or crazing of the products being formed during the carrying out oi the process, in which the strength or the resultant products immediately after steam treatment is above or at least equal to the normally aged productsnow appearing on the market. Furthermore, the process edects a modification of the color of the basic material without destro 'ind the coloring eiiect of the added coloring material.V Additionally, the invention contemplates a` process in which concrete products having the qualities mentioned canV be formed in a relatively short time to thereby permit the ready release or the equipment in which the process is carried out, so that the same equipment may be used for the iormationot other products, and in which the products before removal from the equipment have attained approximately Ytheir maximum strength.

Other objects and advantages will be apparent from the following detailed description when considered in connection with the accompanying drawings, wherein I have illustrated a preferred system in which the invention may be carried out. However, itis to. be understood that the more detailed description and illustration is an exempliication of the invention and the invention is not limited thereto. ln the drawings,

Figure l is a diagrammatic view of a system for carrying out the invention;

Fig. 2 is a graph showing the time curve with relation to steam pressure, and showing the pressure and time involved in the treatment of products iormed with the diiierent coloring` materials specified in the two specific examples hereinafter set forth; i Y

New referring to the drawings in detail, the numeral l designates a mixing device wherein cement, sand and gravel or other aggregates, with or without color and water, are mixed. The coloring matter mayV vary in quantity to give tints, solid colors, blended, or other varied effects. Water should 'be added to this mixture so that it ispreferably l of a quaking consistency. A suicient quantity ot this mixture is then placed in a pallet or multiple vibrating mold, such as indicated at 2, to Jform a layer of a thickness desired upon the bottom thereof. This material in the mold isthen vibrated, upon the vibrating support 3, a. suicient length of time to make a fairly 'uniform layer or coating of concrete in the bottom of each mold, and due to the vibration the coloring material forms uniformly or in a varied lmanner depending on the length of time, violence ot' the vibration, and the degree of mixing and consistency to which the mixture has previously been subjected.

Another mixing device 4 is arranged adjacent the mixing device l, and the multiple mold 2 is so mounted that it may be moved under either mixing device to receive mate- `rial discharged therefrom.

After the facing material has been deposited in the mold 2 and vibrated to form a uniform layer upon the bottomthereof, it is moved to a position beneath the mixing device 4. A mixture of cement, sand and gravel or other aggregate, with the addition of water, which has been produced in the mixing device 4, which mixture may be semidry, vwith sufficient water for thorough hydration during the process, or may contain sufficient Water to be of a quaking consistency, is then discharged into the multiple vibrating mold 2 upon the layer or coating of facing material which was mixed in the mixing device l. Care should be taken to make sure that the interim between the depositing of the facing material and the backup material is` not sufficient to permit the facing material to harden to any degree.

The mold is again placed on the support 3 .1 and `vibrated a suilicient length of time to permit uniting of the face and the back-up portions by a relative penetration of one into the other. The amount of material discharged into the mold 2 from the mixing device 4 governs the thickness of the pro-duct produced, and it may be varied according to the manner in which the products are to be used in the building construction. Should it be desired to have the unit used in the 4building construction by extending from the vice or mold.

`Each mold 2 is adapted to be'moved, either manually: or by means of a crane, to a position upon the vvibrating support 3. the supsie After the'mold 2k has'been' filled, itis adapted to be engaged by hooks 'associated With the crane lfor supporting and carrying the same to a point Where it is deposited upon a car indicated at 7. propelled along a track 8. lA` series of the molds withthe material contained therein Lio `may be arranged uponthe flat car'7 asindicated at 9, and thecar ymoved along the track 8 into a steam chamber indicated at 10.v The steam chamber Yor cylinder k10`is providedV vvithan` entrance 'door 11, or with a pair of doors arranged at the 'entrance and exit ends respectively, so that when the car with the pallets contained thereon Ais moved into the chamber, the pallets substantially Vi'llthe cross sectionalarea'of the cylinder `and 'the dooror doors'may be closed. The door `11,

Vor both the doors, are so constructed that a steam pressure can be built yup vWithin* the cylinder A10 Without substantialescape of the steam.therethrough. p

A steam generatorflrQisprovided andan inlet pipe 13 is arranged between the generator and the cylinder 10 for conducting the steam thereto. An outlet or exhaust port 14 isprovided in thek Wall ofl the cylinder for the purpose kof permitting the escape n ofV steam or air therethrough as desired. n

After the door `or doors areclosed, steam is admittedthrough the inlet pipe 13under the control of the valve 15arranged therein,

While the exhaust port under` the control of the valve 16`inpipe v14 isr permitted toj re- Y opened slightlyfarther at intervals, and the l pressure Within the cylinder is permitted to increase until substantiallylOOelO lbs'. per square inch is reached. This `pressure of- 100-150 lbs; per square inch is maintained f :for several hours, andupon the ,release of .the` steam pressure and the removal of the molds with the products l, contained ltherein from the cylinder, it is found that the units' are eoual to yor -superior lin use tothe 4materials heretofore usedforv similar purposes,

that a sufficient 'shrinkage has, occurred to' permit the readyremoval of;the products from the molds [Without the creation o fany cracksv or Weakppoints atjthe` juncture', between the face and back-up `portions thereof,

Yand that the strength is suchthatnegligible `breakage results from" the handling'of said Y' i l y f therein', were engaged by hook members as-4 sociated Vvvitha crane and placed uponr a car,-

r units..

My experiments have demonstrated that in The cary7- is adapted to be f they curing .of kconcrete products AWith steam and 4high pressure, ythe critical period. develops in the `early stages of admitting steam to the chamber, due `to the excessmoisture contained in the units inftheir green' or natu-U` `rally' formed state. Only suiicient steam was admitted to expel'the contained yair in' the.V chamber, and it Was admitted gradually in sufficient. quantity to raise thetemperature'of Y l 'contained to the temperaturey of steam ataty the chamber and the concrete units therein mospheric pressure, tozthereby drive out of lthe concrete units the excess moisturewthey originally contained. If steam at` pressureis yintroducedrbefore thetemperature of the units is raised to that of the steam at atmospheric pressure, the absorbing of the excess moisture fromtheunits will take place only immediately adjacent the surface and .the

condition of hardening vof :the outer portion yof the unit will'arise. Such acondition causes the excess moisture in the interior of the unit,

when escaping,- tof rupture the unit and effect cracks or laminationsvvhich tend to destroy the strcngthrand effectiveness of the unit als a masonry building'structure.

arethatirst, in the preparation of the facing material theV mixtures ranging from semi-dry to a qualnng consistency and ofthe propor- Were prepared, vin conjunction with a suliicient quantity of a ferrie oxide coloring medium, and the mixturesfwith the coloring medium further rmixed to the desired degreev toproduce a uniform color, vor a variegated color as desired. The mixtures thus prepared 'were :placed in the multiple molds and vvibrated by means of ari-unbalanced weight vi!` bratori for a period of time sufficient to imake l the same substantially homogeneous, and also suiiclent to'cause the surfacefinv Contact With multiple molds upon the facing material val- 4:ready therein..y Ank further vibration ofthe rmolds was then caused .byvmeansfof .the un-y balanced Weight vibrator, and the vibration Specific examplesvvhich I have carried out 1 .tions of one partPortland cement, four parts sand, andsixparts crushed stoneor gravel was continued for afperiod of time suiiicient f to` Vmake kthe back-upf material homogeneous f yWithout effectingy a penetration of the backup material intothe facingyma'terial to an extent bevond that necessaryto form a. firm bond.

rrrlhe molds, with the material v contained which latter wasmoved along a track and into a steam cylinder. The doors of the cylinder were closed and an exhaust valve opened, afterV `which steam was gradually vintroduced into the cylinder to drive out the air present therein and to raise the temperature of the cylinder very gradually until a temperature of 212 F. was reached. After reaching the temperature of 212 F. within the cylinder, the exhaust valve was closed and the steam valve only partially openedin the same manner as in driving out of the air and the heatingof the interior of the cylinder. The steam valve was permitted to remain in this position for a period of approximately minutes, and thereafter it was Opened by degrees until a steam pressure of approximately 100 lbs. to 150 lbs. was reached. VThe steam pressure of 100 lbs. to 150 lbs. per square inch was maintained within the cylinder for substantially eight hours,`whereupon the exhaust valve was openedy and release of y the steam pressure was effected.

l/Vhen the molds were withdrawn'from the cylinder and the molded productsl removed, it was found Vthat the products were equal to normal products which have previously been made by other methods of curing, as air curing and curingin steam at atmospheric pressure and ata time after they had been per- Vmitted vto age for a period of QSdays. The faces of the products were of a variegated character and of a pleasingappearance which resembled high grade natural rock.

Due to the above treatment at the time of removal from the steam cylinder the products were shrunk to an extent where they could be readily removed from the molds, and to an extent where material shrinkage was minimized when the products were placed in products having an appearance of a white Vbackground with a cloudedor mottled effect,

buildingl structure, and a. firm bond was had between the facing and bach-up portions so that unitsk in use resembled natural stone.

Other specific examples which I have carried out involved the production of lightweight units, and the'facing portions of the units were produced identically asset forth in the above examples. However. in the pro duction of the back-up material to render the entire units of aL liffht-weight character,{ Y

the Weight of thecement used inthe facing Vmaterial is added and mixed vin such a manner a mixture of one .partof Portland cement, live parts of glacial sand of the typefound in the southwestern part of Ohio, and seven parts of crushed stone or gravel capable of pass through a 3/8 inch screen, with the stonej:

or lgravel preferably in the form of irregular fragments, was produced, with a thorough mixture with water to an extentof approxi` Vsettling and compacting of the materiallto Vsome extent, but not sufficient `to effect `a formation of alayer of cement and sand sep'- arately from the Aaggregate upon the surface of the products, or at the face of contact of Ypi'eofed on that portion which isrexposed to the atmosphere when used in ja building construction.

` y Various types'of coloring matter which will withstand the bleaching action of high pressure steam may be used, as, for example,

chemical, mineral, vegetable and metallic coloring agents. However, l have found the chemically pure rmetallic oxides to be best suited for most products. These may range from black into the various shades of browns, reds, greens, yellows and orange. The amountrof coloring matter to be added depends uponthe effect to be produced, the tinting power ofthe color, and the extent toV which it bleached in the steam treatment.

`Since. the steamtreatment turns the basic material of `the standard concrete mixture naturally white in color, the coloring agent need only be added in sparing amount from 2% to for the tints, and not more than about 10% for the solid colors, Vall Weights being calculated onV the weight of the cement usedfiiithe facing material. The coloring material w1ll also preferably be in thek form of a very fine powder, insoluble in water,

alkaline, and acid and sun-proof.

When -it is desired to produce concrete I find thatthe employment of metallic 'colioring material as ferrie oxide -is preferred Vsince thesteamtreatment, although tending to bleach the normal color of the cement mixture, `does not produce an appreciable bleaching effect u-pon the coloring. and with each of the specific examples outlined above, black oxide of iron -to an extent of 215% of to give the desired effect on the face.

VIf -it is desired to produce a travertine or streaked effect of light brown-with a backgroundof light yellow, the facing material is mixed inthe regularway With one part cement, about 3% of-.yellow beingadded and thoroughly mixed therewith. VThis will give the light yellow background. Brown color to theextent'of about3% 'is then mixed theresulting mixture is then spread on the bottom 'of the mold in streaks or spots, after which the remainder of the mixture, which forms the yellow background, is added tothe VYwith one-quarterlofthe; above'mixture, and

desired thickness. The vback-up material is then added and the unit completed `aps-has already'been set forth., f v As will be obvious, the abovel examples maybe varied in many ways withrespectto color and the particular elfectdesired on the faceof the unit. They yare merely given as illustrative examples. t

AThe graph illustrated injFig. 2 `shows the preferred mannerk of controlling thek admission of the steam to the cylinder and the-control of the steam pressure; throughout the treatment of the produ-cts. It will benoted that the reading of the graph is thej'same as the specific examples of the testlieretofore v made and referred to above.vr

An outlet or drain 17 is employed for permittinga drainage of any waterthat may result from condensation withinv the cylinder'` during any. stage of the treatment.

'In so far as the eneral steam treatment of the units producey `by the present method is concerned, it is substantially identical with the steam treatment of concrete products as described and claimed in myapplication Serial No. 354,362, and the equipment employed is the same except that the'present equipment for carrying out the completefprocess embodies the means` for producing ,the `facing 1` and back-up material so that onemay be,v

joined to the other.` l

The feature ofproducing the light weight backing is substantially the same as described and claimed inmy Vapplication Serial No. 354,363, and the equipment for vibrating themold to carry out this part of the process is operated substantially as described in said application Furthermore, in the production ofthe light-weight back-up material l".

have employed cinder slag and other light weight aggregates of a manufactured character, and find that said mat'erialcan be substituted in-whole or :,inpart with quite eilicient results. f

Iclaim: i

1. The method of preparing-faced concrete products' which comprises lprepa-ring a mixture of facing material and effecting a'deposit thereof in amold, preparing amixture vof backing material `and effecting a deposit thereof in the mold upon the facing material,

subjecting the materialswhile inthe mold to vibration and to the actionof steam at substantially atmospheric pressure until the temperature thereof `is substantially that of steam, and thereafter subjecting the materials to steam at a pressure in excess of that of the atmosphere.- e f 2. The method of preparing faced 'concrete products which comprises preparing a mixture of facing material and effectinga `deposit thereof in a mold, preparing a mixture of backing material andeifectingfa ydeposit thereof inthe mold upon the Vfacing material,`

subjecting the materials while in the mold to action of steam at substantially atmospheric pfpressure'until the temperature thereofv is lsubu ing one part cement, five parts sand, and sevand cement. l l .c

5.1'The method of'preparing light weight.z

' f y6. They method vibration and to the action of steam at sub- Y stantially atmospheric pressure until the temperature thereof is approximately 212"y F., and then increasing the pressure of the steam to which theproduct'is subjected to between 100 lbs. and 150 lbs. pressure per square inch n suilicient water kto permit'hydration, effecting a deposit of the back-up material inthe -mold'upon the facing material to an extent to .cause t e finished productto be of a predetermined thickness, -again vibratingl themold with the facingv andback-up materials there- Ain to cause a firm bond between the same,and subjecting thejmaterials in the mold` to the stantially that zof steam vand thereafter subjecting the materials to steam at a' pressure ink excess-of that ofithe atmosphere.

4. The methodl of preparinglight weight faced concrete products, whichcomprises ,preparing a mixtureof facing ,material and y 1 effecting a deposit thereof in a mold,pre'paring a mixture of back-up material compris- .en parts gravel orcrushed stone, and-thoroughly mixing the ingredients' with the adldition kof water from vsix'to eightpercent'by suflicientfto effect-stratification ofthe sand faced concretek products which comprises preparing ka Imixture, of facing material and efvfecting adeposit thereof in amold, preparing a mixture' ofback-.up e material lcomprising one part cement, `five parts sand,and seven i .weight of said backup mixture, depositing ,the back-up mixture inthe mold upon the' .facing material andv vibrating the-mold ysufis -ciently to/fo'rm abondbetween the mixtures {andftosettle and compact the-mixture but inparts Vgravell and crushed stone. and -thor- .oughly mixing the ingredients with-the yaddition of `water from-6% to 8%L by weight of said back-up mixture, depositing the back-up AInixturein the mold upon the facing material and vibrating the mold for substantially fty seconds at speed of about 3600 vibrations per minute to lform a bond between the mixtures and lto settle and compactthe mixture -without effecting stratification'of the cement and J sand.

faced lconcrete products Vwhich vcomprises ypreparing a mixtureof facing materialand effecting a deposit thereof ina mold, preofpreparing lightweight i paring the mixture of back-up material as of cinders, previously crushed down to passa three-eighth inch screen with dust and ash removed, comprising eight parts cinders passed through vthree-eighth inch Vscreen Y upon a three-sixteenth inch screen; and eight partsk of cinders passed through a three-sixteenth inch screen, one part cement, and from 5% to 20% calcined gypsum or plaster of Paris calculated on the weight of cement used in the back-up, the calcined gypsum or plaster of Paris being used to increase the setting action and hydration of cement and making the backeup material of dryer consistency, and thoroughly mixing the ingredients with theaddition of Water from 6% to 8% `by Weight of said back-up mixture, depositing the back-up mixture in the mold upon the fac backin thereof is in contact with the bottom ofthe same, vibrating the mold With thematerial therein to produce a` desired facing on the 'finished y product, preparing a` mixture of material and effecting a deposit thereo in themold upon the facing material, subjecting the materials While in the mold to vibration and to the actionfof steam at substantially `atmospheric pressure until the temperature thereof vis substantially that of steam, and thereafter subjecting the materials to'steam at 100 lbs. to 150 lbs. pressure per square inch for approximately six to eight hours.

In testimony whereof I'afiixmy signature.

WILLIAM H. CRUME.

ing material and Vibrating themold for sub- A stantially fifty seconds at a speed of about 3600 Vibrationsper minute to form a bond between the mixtures and to settle and compact the mixture Without effecting stratification of the cement and cinders.

7'. The method of preparing faced concrete products which comprises preparing a mixture of facing material With coloring matter incorporated therein and effecting a deposit thereof in a mold, preparing a mixture of backing material and effecting a ,deposit thereof in the mold upon the facing material, subjecting the materials While in the mold'to Vibration, and subjecting the facing mate'- rial to a treatment tending to bleach the color of the material Without unduly bleaching the coloring matter.

8. The method of preparing faced concrete products Which comprises preparing a `mixture of facing material with coloring matter incorporated therein, further preparing fac- L Y I ing material differing in color and depositing the same in streaks or spots on the bottomof a mold, depositing the first-mentioned facing material Within the mold so that a portion thereof is in contact with the bottom ofthe same, vibrating the mold with the material therein to produce ya desired facing onrthe finished product, preparing a mixture of i backing material and effecting a deposit thereof in the mold upon the facing material,

subjecting the materials While in the mold to vibration andto the action of steam at subistantially atmospheric pressureuntil the temperature thereof is `substantially that of steam, and thereafter subjecting the' materials to steam and a pressure in excess of that of the atmosphere.

9. The method of preparing faced concrete products Which comprises preparing a mixture of facing material With coloring matter incorporated therein, further preparing fac ing material differing in color and depositing the same in streaks or spots on the bottom of a mold, depositing the first-mentioned facing material Within the mold' so that a portion 

